To model a biphasic stirred tank reactor, intrinsic reaction kinetics and interfacial area are required. In this study, reactor modeling for n-butyraldehyde aldol condensation was investigated under industrially relevent conditions. The interfacial area in the reactor was directly measured using a borescope system under appropriate temperature, NaOH concentration and rpm conditions. To estimate the interfacial area, a semi-empirical correlation was developed, which provides good estimates within ±15% error. The reactor model based on two-film theory was developed, combining the interfacial area and intrinsic reaction kinetics reported in our prior work. The model was verified by reaction experiments in the range 0.05-1.9M NaOH, 80-130 o C and 600-1000 rpm. The prediction errors using the interfacial area from direct measurements and the correlation were ±8% and ±15%, respectively, suggesting that the model accuracy may be improved with better interfacial area estimation.Topical Area: Reaction Engineering, Kinetics and Catalysis
This work addressed liquid−liquid mass transfer for actual industrial conditions of high pH with coexisting salt. The Sauter mean diameter was determined from the direct measurement of a chlorobenzene droplet size using a borescope system. At a high NaOH concentration, the droplet size decreased significantly due to the reduced density difference between two phases, and it further decreased when NaOH and NaCl coexisted. A Sauter mean diameter correlation with a density difference term was proposed, and it successfully predicted the experimental results. To determine the mass transfer coefficient, the solubility and the concentration gradient of chlorobenzene in the aqueous phase were measured under various conditions. As the NaOH and NaCl concentration increased, the solubility of chlorobenzene and the rate of change of chlorobenzene concentration in the aqueous phase both decreased, but the decrease in solubility was more pronounced. Thus, the mass transfer coefficient increased with the NaOH and NaCl concentration.
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